New mechanistic cutting force model for milling additive manufactured Inconel 718 considering effects of tool wear evolution and actual tool geometry

The objective of this paper is to present a methodology to analytically model the tool flank wear rate in near-dry turning. The resulting models can serve as a basis to minimize time-consuming machining tests in predicting tool life. Analytical models, including cutting force model, cutting temperature model, and tool wear model, are presented. The cutting force model was established based on Oxley’s model with modifications for lubricating and cooling effect due to the air-oil mixture in near-dry machining. The cutting temperature was obtained by considering a moving or stationary heat source in the tool. The tool wear model contained abrasive mechanism, adhesion mechanism, and diffusion mechanism. The important factors related to this model were contact stresses and temperatures that were obtained from the cutting force model and the cutting temperature model. To develop these models, a set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the coefficients in the models and to verify the proposed flank wear mechanisms. The comparisons between the model-predictive flank wear and experimental results showed that the flank wear in near dry machining can be estimated well by the proposed models. It was also found that the cutting velocity was a dominant factor among the cutting conditions.

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Studies on Tool Wear Monitoring Based on Cutting Force

Materials Science Forum ◽

10.4028/www.scientific.net/msf.697-698.268 ◽

2011 ◽

Vol 697-698 ◽

pp. 268-272 ◽

Cited By ~ 1

Author(s):

Mao Hua Xiao ◽

Ning He ◽

Lei Li

Keyword(s):

Tool Wear ◽

Cutting Force ◽

Flexible Manufacturing ◽

Manufacturing System ◽

Force Model ◽

Cutting Force Model ◽

Monitoring Tool ◽

Cutting Test ◽

On Line ◽

Wear Monitoring

On-line tool wear sensing was an important subject in the Flexible Manufacturing System. Mathematic method is applied in this paper to analyze the correlation between cutting force and tool wear, and a cutting force model was established based on the tool wear. The predicted value of cutting force was calculated through the cutting test. Predicted value by comparison with the experimental data verifies the accuracy of the cutting force model. On this basis, a new method for monitoring tool wear based on measuring cutting force was proposed.

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Identification of eccentricity for disc milling cutter of indexable two sided inserts

Advances in Mechanical Engineering ◽

10.1177/16878140211041493 ◽

2021 ◽

Vol 13 (8) ◽

pp. 168781402110414

Author(s):

Gensheng Li ◽

Chao Xian ◽

Hongmin Xin

Keyword(s):

Tool Wear ◽

Machine Tool ◽

Cutting Force ◽

Cutting Forces ◽

Theoretical Method ◽

Force Model ◽

Cutting Force Model ◽

Milling Cutter ◽

Machining Quality ◽

Operation Status

Tool eccentricity has a significant impact on machining quality, accuracy, and operation status of machine tool. It is difficult to accurately identify tool eccentricity. In this paper, the mathematical models of instantaneous undeformed cutting thickness and cutting force considering tool eccentricity are determined by theoretical method. Based on the model, the identification method for eccentricity parameters is proposed, and the eccentricity parameters of disc milling cutter is identified. According to the identified parameters, the cutting force is verified. The results show that most of the values of measured cutting forces are greater than the predicted ones considering tool eccentricity. In the future, it is necessary to establish a new cutting force model considering both tool eccentricity and tool wear.

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Modeling and Analysis of Machining Force in Elliptical Vibration Cutting

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.690-693.2464 ◽

2013 ◽

Vol 690-693 ◽

pp. 2464-2469 ◽

Cited By ~ 1

Author(s):

Jie Qiong Lin ◽

Jian Hua Liu ◽

Xiao Ping Gao ◽

Shu Qing Wang

Keyword(s):

Cutting Force ◽

Cutting Parameters ◽

Theory Model ◽

Tool Geometry ◽

Force Model ◽

Cutting Force Model ◽

Elliptical Vibration Cutting ◽

Vibration Cutting ◽

Elliptic Motion ◽

Elliptical Vibration

Elliptical vibration cutting (EVC) is one of the main methods to use diamond tool machining of hard to cutmaterial. Accurate prediction of cutting force in elliptical vibration cutting process is not only an important basis to properly choose of cutting parameters and optimal tool geometry parameters, but also a key factor to improve the processing property of cutting. A method to build cutting force theory model in EVC is presented in this paper. Eigen decomposition of the elliptic motion locus first ,then getting the piecewise function of the cutting force model. Based on simulation analysis of the cutting force model, this paper predict the rules that vibration amplitude and angle of tool geometry affect on cutting force, which provide theory basis for choose cutting parameters and cutting tool parameter in EVC.

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